Heterophasic propylene copolymer composition with low gloss

ABSTRACT

The present invention relates to a polymer composition comprising a first heterophasic propylene copolymer, a second heterophasic propylene copolymer and optionally an inorganic filler. The present invention further relates to a process for the preparation of said polymer composition. The present invention further relates to an automotive part comprising such polymer composition.

The present invention relates to a polymer composition comprising afirst heterophasic propylene copolymer, a second heterophasic propylenecopolymer and optionally an inorganic filler. The present inventionfurther relates to a process for the preparation of said polymercomposition. The present invention further relates to an automotive partcomprising such polymer composition.

Polymer compositions, especially polymer compositions based onpolypropylene are widely used in automotive industry thanks to theirexcellent mechanical and chemical properties. Low gloss materials arepreferred for Automotive interiors. High gloss Automotive interiorsurface of may cause strong light reflection and may also affect thecomfort of the driver potentially increasing the risk of trafficaccidents.

As is known, low gloss can be realized by the addition of a mattingmodifier in the polymer composition. Matting modifiers are oftenparticles with size smaller than 900 nm, for example:

CN102807703B discloses a low gloss polypropylene composition, comprisingthe following components: polypropylene, matting modifier; wherein thepolypropylene is 100 parts by weight, the matting modifier 1˜20 parts byweight; the said matting modifier comprises powdered nitrile rubber,grafted polypropylene and an inorganic material.

CN102532774A discloses a low gloss polypropylene composite materialwhich is prepared from the following raw materials by weight percent:45-99% of polypropylene, 0-42% of inorganic filling material, 0-10% ofpolyolefin elastomer, 0.5-4% of organic delustering agent, 0.1-2% ofantioxidant and 0-3% of other additives.

CN102108175B discloses a low gloss and high toughness polypropylene, itis made from the following percentages by weight of raw materials:polypropylene 55˜91, 25˜0 inorganic filler, plasticizer 0 to 10, nanomontmorillonite 1 to 5, maleic anhydride grafted polypropylene(PP-g-MAH) 2˜4, an antioxidant of 0.1 to 1, other additives 0 to 1.

However matting modifiers may decrease the overall properties of thepolymer composition e.g. a deteriorated mechanical performance or anunpleasant smell.

Hence, there is a need in automotive industry to have a polymercomposition having low gloss and good mechanical performance. Inavoidance of any confusion, “mechanical performance” refers to impactresistance and stiffness.

This need is satisfied in the present invention by a polymer compositioncomprising a first heterophasic propylene copolymer (a), a secondheterophasic propylene copolymer (b) and optionally an inorganic filler,wherein the amount of the first heterophasic propylene copolymer (a) isin the range from 4.6 to 70.4 wt % based on the total amount of thepolymer composition, wherein the amount of the second heterophasicpropylene copolymer (b) is in the range from 4.3 to 69.8 wt % based onthe total amount of the polymer composition,

wherein the first heterophasic propylene copolymer (a) comprises:

-   -   from 80 to 92 wt % of a propylene polymer (a1), wherein the melt        flow index (MFI) of the propylene polymer (a1) is in the range        from 150 to 300 dg/min as determined according to ISO1133-1:2011        at 230° C. with 2.16 kg load;    -   from 8 to 20 wt % of an ethylene-α-olefin copolymer (a2),        wherein the moiety of α-olefin in the ethylene-α-olefin        copolymer (a2) is derived from at least one α-olefin having 3 to        20 carbon atoms;

wherein the MFI of the first heterophasic propylene copolymer (a) is inthe range from 40 to 120 dg/min as determined according to1501133-1:2011 at 230° C. with a 2.16 kg load.

wherein the second heterophasic propylene copolymer (b) comprises:

-   -   from 65 to 81 wt % of a propylene polymer (131),    -   from 19 to 35 wt % of an ethylene-α-olefin copolymer (b2),        wherein the moiety of α-olefin in the ethylene-α-olefin        copolymer (a2) is derived from at least one α-olefin having 3 to        20 carbon atoms,

wherein the MFI of the second heterophasic propylene copolymer (b) is inthe range from 10 to 100 dg/min as determined according toISO1133-1:2011 at 230° C. with 2.16 kg load,

wherein the MFI of the polymer composition is in the range from 5 to 100dg/min as determined according to ISO1133-1:2011 at 230° C. with 2.16 kgload.

It was surprisingly found that the polymer composition according to thepresent invention has low gloss and good mechanical properties.

HETEROPHASIC PROPYLENE COPOLYMER

A heterophasic propylene copolymer typically has a two-phase structure,comprises a propylene-based semi-crystalline polymer as matrix and adispersed elastomer phase, usually an ethylene-α-olefin rubber.Heterophasic propylene copolymers are usually prepared in onepolymerization process.

The First Heterophasic Propylene Copolymer (a)

The first heterophasic propylene copolymer (a) comprises a firstpropylene polymer (a1) as matrix and a first ethylene-α-olefin copolymer(a2) as dispersed phase.

The amount of the first propylene polymer (a1) is in the range from 80to 92 wt %, preferably from 85 to 90 wt % based on the total amount ofthe first heterophasic propylene copolymer (a).

The first propylene polymer (a1) in the first heterophasic propylenecopolymer (a) can be a propylene homopolymer or/and a propylene-α-olefincopolymer wherein the α-olefin has 2 or 4 to 20 carbon atoms, forexample the propylene-α-olefin can be a propylene-ethylene copolymer ora propylene-butene copolymer. Preferably the first propylene polymer(a1) in the first heterophasic propylene copolymer (a) is a propylenehomopolymer.

The melt flow index (MFI) of the first propylene polymer (a1) in thefirst heterophasic propylene copolymer (a) is preferably in the rangefrom 150 to 300 dg/min, preferably from 180 to 270 dg/min, morepreferably from 200 to 250 dg/min as determined according toISO1133-1:2011 at 230° C. with 2.16 kg load.

The amount of the first ethylene-α-olefin copolymer (a2) is preferablyin the range from 8 to 20 wt %, preferably from 10 to 15 wt % based onthe total amount of the first heterophasic propylene copolymer (a).

In the first heterophasic propylene copolymer (a), the amount of themoiety derived from ethylene is preferably in the range from 40 to 53 wt% based on the total amount of the first ethylene-α-olefin copolymer(a2).

The moiety of α-olefin in the first ethylene-α-olefin copolymer (a2) inthe first heterophasic propylene copolymer (a) is preferably derivedfrom at least one α-olefin having 3 to 20 carbon atoms, for example thefirst ethylene-α-olefin copolymer (a2) can be an ethylene-propylenecopolymer, for example the first ethylene-α-olefin copolymer (a2) can bean ethylene-butene copolymer, for example the first ethylene-α-olefincopolymer (a2) can be an ethylene-hexene copolymer, for example thefirst ethylene-α-olefin copolymer (a2) can be an ethylene-octenecopolymer, for example the first ethylene-α-olefin copolymer (a2) can bean ethylene-propylene-butene copolymer, for example the firstethylene-α-olefin copolymer (a2) can be an ethylene-propylene-hexenecopolymer. Preferably the first ethylene-α-olefin copolymer (a2) in thefirst heterophasic propylene copolymer (a) is an ethylene-propylenecopolymer

Preferably the MFI of the first heterophasic propylene copolymer (a) isin the range from 40 to 120 dg/min, more preferably from 40 to 100dg/min, most preferably from 60-100 dg/min, as determined according toISO1133-1:2011 at 230° C. with a 2.16 kg load.

The first heterophasic propylene copolymer (a) can be divided into afirst xylene-soluble portion (First CXS) and a first xylene-insolubleportion (First CXI). The amount of the xylene-soluble portion of thefirst heterophasic propylene copolymer (a) is in the range from 10 to 27wt %, preferably from 10 to 16 wt % based on the total amount of thefirst heterophasic propylene copolymer (a) as determined according to15016152:2005. The amount of the first xylene-insoluble portion based onthe total amount of the first heterophasic propylene copolymer iscalculated by the following equation:

First CXI=100 wt %−First CXS

The ratio between the intrinsic viscosity of the xylene-soluble portionof the first heterophasic propylene copolymer (a) IV_(First CXS) and theintrinsic viscosity of the xylene-insoluble part of the firstheterophasic propylene copolymer (a) IV_(First CXI) is in the range from3.1 to 7.2, preferably from 3.2 to 5.1, wherein IV_(First CXS) andIV_(First CXI) are measured according to ISO1628-1:2009 andISO1628-3:2010 respectively.

The intrinsic viscosity of the first xylene-insoluble part (First CXI)of the first heterophasic propylene copolymer (a) IV_(First CXI) is inthe range from 1.0 to 2.0 dl/g, more preferably from 1.0 to 1.8 dl/g,more preferably from 1.1 to 1.5 dl/g, even more preferably from 1.2 to1.4 dl/g as measured according to ISO1628-3:2010.

The intrinsic viscosity of the first xylene-soluble part (First CXS) ofthe first heterophasic propylene copolymer (a) IV_(First CXS) is in therange from 4.5 to 6.5 dl/g, more preferably from 4.8 to 6.5 dl/g, evenmore preferably from 4.8 to 6.0 dl/g as measured according toISO1628-1:2009.

The first heterophasic propylene copolymer (a) is preferably anon-visbroken heterophasic propylene copolymer. The term non-visbrokenis known in the art, yet for the avoidance of doubt it means that thematerials was not treated such as to modify the molecular weight and/orthe molecular weight distribution of the polymer directly afterpolymerisation. In other words, non-visbroken polymers are not treatedwith peroxides, radiation, or any other initiating source for chainbreaking reactions to occur. An advantage of non-visbrokenpolypropylenes over vis-broken polypropylenes is that the formergenerally suffer less from the release of low molecular weightmaterials, such materials inherently being produced upon visbreaking andis not desired for automotive application. For the avoidance of doubt,the term reactor grade indicates that the copolymer is non-visbroken.The first heterophasic propylene copolymer (a) is preferably a reactorgrade heterophasic propylene copolymer.

The process to produce the first heterophasic propylene copolymer (a) isknown in the art. Preferably the first heterophasic propylene copolymer(a) is produced in a sequential polymerization process comprising atleast two reactors, more preferably the polypropylene of the presentinvention is produced in a sequential polymerization process comprisingat least three reactors.

The catalyst used in the preparation of the first heterophasic propylenecopolymer (a) is also know in the art, for example Ziegler-Nattacatalyst, metallocene catalyst. Preferably the catalyst used to producethe first heterophasic propylene copolymer is free of phthalate, forexample the catalyst comprises compounds of a transition metal of Group4 to 6 of IUPAC, a Group 2 metal compound and an internal donor whereinsaid internal donor is a compound selected from optionally substitutedmalonates, maleates, succinates, glutarates,cyclohexene-1,2-dicarboxylates, benzoates, citraconate and derivativesand/or mixtures thereof.

For example the catalyst used in the preparation of the firstheterophasic propylene copolymer (a) is a Ziegler-Natta catalystcomprising a procatalyst, at least one external donor, a co-catalyst andan optional internal donor wherein the external electron donor is chosenfrom the group consisting of a compound having a structure according toFormula III (R⁹⁰)₂N—Si(OR⁹¹)₃, a compound having a structure accordingto Formula IV: (R⁹²)Si(OR⁹³)₃ and mixtures thereof, wherein each of R⁹⁰,R⁹¹, R⁹² and R⁹³ groups are each independently a linear, branched orcyclic, substituted or unsubstituted alkyl having between 1 and 10carbon atoms, preferably a linear unsubstituted alkyl having between 1and 8 carbon atoms, preferably ethyl, methyl or n-propyl.

In one embodiment, R⁹⁰ and R⁹¹ are each ethyl (compound of Formula IIIis diethylaminotriethoxysilane, DEATES). In another embodiment, R⁹² isn-propyl and R⁹³ are each ethyl (compound of Formula IV is n-propyltriethoxysilane, nPTES) or in another embodiment R⁹² is n-propyl and R⁹³are each methyl (compound of Formula IV is n-propyl trimethoxysilane,nPTMS).

Preferably, the heterophasic propylene copolymer of the invention is isprepared by a catalyst system comprising a Ziegler-Natta catalyst and atleast one external electron donor chosen from the group of a compoundhaving a structure according to Formula III (R⁹⁰)₂N—Si(OR⁹¹)₃, acompound having a structure according to Formula IV: (R⁹²)Si(OR⁹³)₃ andmixtures thereof.

A “co-catalyst” is a term well-known in the art in the field ofZiegler-Natta catalysts and is recognized to be a substance capable ofconverting the procatalyst to an active polymerization catalyst.Generally, the co-catalyst is an organometallic compound containing ametal from group 1, 2, 12 or 13 of the Periodic System of the Elements(Handbook of Chemistry and Physics, 70th Edition, CRC Press, 1989-1990).The co-catalyst may include any compounds known in the art to be used as“co-catalysts”, such as hydrides, alkyls, or aryls of aluminum, lithium,zinc, tin, cadmium, beryllium, magnesium, and combinations thereof. Theco-catalyst may be a hydrocarbyl aluminum co-catalyst, such astriisobutylaluminum, trihexylaluminum, di-isobutylaluminum hydride,dihexylaluminum hydride, isobutylaluminum dihydride, hexylaluminumdihydride, diisobutylhexylaluminum, isobutyl dihexylaluminum,trimethylaluminum, triethylaluminum, tripropylaluminum,triisopropylaluminum, tri-n-butylaluminum, trioctylaluminum,tridecylaluminum, tridodecylaluminum, tribenzylaluminum,triphenylaluminum, trinaphthylaluminum, and tritolylaluminum. In anembodiment, the cocatalyst is selected from triethylaluminum,triisobutylaluminum, trihexylaluminum, di-isobutylaluminum hydride anddihexylaluminum hydride. More preferably, trimethylaluminium,triethylaluminium, triisobutylaluminium, and/or trioctylaluminium. Mostpreferably, triethylaluminium (abbreviated as TEAL). The co-catalyst canalso be a hydrocarbyl aluminum compound such astetraethyl-dialuminoxane, methylaluminoxane, isobutylaluminoxane,tetraisobutyl-dialuminoxane, diethyl-aluminumethoxide,diisobutylaluminum chloride, methylaluminum dichloride, diethylaluminumchloride, ethylaluminum dichloride and dimethylaluminum chloride,preferably TEAL.

For example, the procatalyst may be prepared by a process comprising thesteps of providing a magnesium-based support, contacting saidmagnesium-based support with a Ziegler-Natta type catalytic species, aninternal donor, and an activator, to yield the procatalyst. For example,the Examples of U.S. Pat. No. 5,093,415 of Dow discloses an improvedprocess to prepare a procatalyst. Preferably, the procatalyst is achemical compound comprising titanium.

In the context of the present invention, the molar ratio between Si andTi element in the catalyst system is preferably in the range from 0.1 to40, preferably from 0.1 to 20, even more preferably from 1 to 20 andmost preferably from 2 to 10. Preferably the molar ratio between Al andTi element in the catalyst system is in the range from 5 to 500,preferably from 15 to 200, more preferably from 30 to 160, mostpreferably from 50 to 140.

In one embodiment, the molar ratio between Si and Ti element is themolar ratio between the external donor and the procatalyst.

In one embodiment, the molar ratio between Al and Ti element is themolar ratio between the co-catalyst and the procatalyst.

The Second Heterophasic Propylene Copolymer (b)

The second heterophasic propylene copolymer (b) comprises a secondpropylene polymer (b1) as matrix and a second ethylene-α-olefincopolymer (b2) as dispersed phase.

The amount of the second propylene polymer (b1) is in the range from 65to 81 wt %, preferably from 70 to 75 wt % based on the total amount ofthe second heterophasic propylene copolymer (b).

The second propylene polymer (b1) in the second heterophasic propylenecopolymer (b) can be a propylene homopolymer or/and a propylene-α-olefincopolymer wherein the α-olefin has 2 or 4 to 20 carbon atoms, forexample the propylene-α-olefin can be a propylene-ethylene copolymer ora propylene-butene copolymer. Preferably the second propylene polymer(b1) in the second heterophasic propylene copolymer (b) is a propylenehomopolymer.

The MFI of the second propylene polymer (b1) in the second heterophasicpropylene copolymer (b) is preferably in the range from 20 to 150dg/min, preferably from 50 to 100 dg/min, more preferably from 60 to 85dg/min as measured according to ISO1133-1:2011 at 230° C. with a 2.16 kgload.

The amount of the second ethylene-α-olefin copolymer (b2) is in therange from 19 to 35 wt %, preferably from 25 to 30 wt % based on thetotal amount of the second heterophasic propylene copolymer (b).

In the second heterophasic propylene copolymer (b), the amount of themoiety derived from ethylene is preferably in the range from 55 to 68 wt% based on the total amount of the second ethylene-α-olefin copolymer(b2).

The moiety of α-olefin in the second ethylene-α-olefin copolymer (b2) inthe second heterophasic propylene copolymer (b) is derived from at leastone α-olefin having 3 to 20 carbon atoms, for example the secondethylene-α-olefin copolymer (b2) can be an ethylene-propylene copolymer,for example the second ethylene-α-olefin copolymer (b2) can be anethylene-butene copolymer, for example the second ethylene-α-olefincopolymer (b2) can be an ethylene-hexene copolymer, for example thesecond ethylene-α-olefin copolymer (b2) can be an ethylene-octenecopolymer, for example the second ethylene-α-olefin copolymer (b2) canbe an ethylene-propylene-butene copolymer, for example the secondethylene-α-olefin copolymer (b2) can be an ethylene-propylene-hexenecopolymer. Preferably the second ethylene-α-olefin copolymer (b2) in thesecond heterophasic propylene copolymer (b) is an ethylene-propylenecopolymer.

Preferably the MFI of the second heterophasic propylene copolymer (b) isin the range from 10 to 100 dg/min, preferably from 15 to 80 dg/min,more preferably 23 to 65 dg/min, most preferably from 30 to 50 dg/min,as determined according to 1501133-1:2011 at 230° C. with a 2.16 kgload.

The second heterophasic propylene copolymer (b) is preferably a reactorgrade heterophasic propylene copolymer.

The second heterophasic propylene copolymer (b) can be produced withprocess and catalyst known in the art.

In one embodiment, the second heterophasic propylene copolymer (b) isproduced with the same process as the first heterophasic propylenecopolymer (a).

In one embodiment, the second heterophasic propylene copolymer (b) isproduced with the same catalyst as the first heterophasic propylenecopolymer (a).

Optional Inorganic Filler

The polymer composition according to the present invention may furthercomprise an inorganic filler.

Suitable examples of inorganic fillers include but are not limited totalc, calcium carbonate, wollastonite, barium sulfate, kaolin, glassflakes, laminar silicates (bentonite, montmorillonite, smectite) andmica.

For example, the inorganic filler is chosen from the group of talc,calcium carbonate, wollastonite, mica and mixtures thereof.

More preferably, the inorganic filler is talc. The mean particle size oftalc (D50) of talc is preferably in the range from 0.1 to 10.2 micron,preferably from 0.3 to 8.1 micron, more preferably from 0.5 to 5.2micron, even more preferably from 0.6 to 2.5 micron according tosedimentation analysis, Stockes' law (ISO 13317-3:2001).

Optional Polyolefin Based Elastomer

Optionally the polymer composition according to the present inventioncomprises a polyolefin based elastomer. The polyolefin based elastomeris preferably an ethylene-α-olefin copolymer wherein the α-olefin has 3to 20 carbon atoms, for example the ethylene-α-olefin copolymer is anethylene-propylene copolymer, for example the ethylene-α-olefincopolymer is an ethylene-butene copolymer, for example theethylene-α-olefin copolymer is an ethylene-hexene copolymer, for examplethe ethylene-α-olefin copolymer is an ethylene-octene copolymer or acombination thereof.

Preferably the polyolefin based elastomer is an ethylene-butenecopolymer or/and an ethylene-octene copolymer.

Preferably the amount of moiety derived from ethylene in the polyolefinbased elastomer is in the range from 45 to 90 wt %, preferably from 50to 87 wt %, more preferably from 55 to 85 wt %, more preferably from 57to 70 wt % based on the total amount of the polyolefin based elastomer.

The polyolefin based elastomer according to the present inventionpreferably has a shore A hardness in the range from 44 to 101,preferably from 48 to 92, more preferably from 51 to 79, more preferablyfrom 54 to 68 as measured according to ASTM D2240-15.

The density of the polyolefin based elastomer according to the presentinvention is preferably in the range from 0.853 to 0.905 g/cm3,preferably from 0.859 to 0.896 g/cm3, more preferably from 0.860 to0.882 g/cm3, more preferably from 0.860 to 0.876 g/cm3 as measuredaccording to ASTM D792-13.

The MFI of the polyolefin based elastomer is preferably in the rangefrom 0.2 to 20.0 dg/min, preferably from 0.3 to 14.3 dg/min, morepreferably from 0.4 to 7.2 dg/min as measured according to ASTM D1238-13with a 2.16 kg load at 190° C.

The polyolefin based elastomer may be prepared using methods known inthe art, for example by using a single site catalyst, i.e., a catalystthe transition metal components of which is an organometallic compoundand at least one ligand of which has a cyclopentadienyl anion structurethrough which such ligand bondingly coordinates to the transition metalcation. This type of catalyst is also known as “metallocene” catalyst.Metallocene catalysts are for example described in U.S. Pat. Nos.5,017,714 and 5,324,820. The polyolefin based elastomer may also beprepared using traditional types of heterogeneous multi-sitedZiegler-Natta catalysts.

In one embodiment, the polyolefin based elastomer is a high densitypolyethylene, wherein the MFI of the high density polyethylene is in therange from 2.3 to 19.8 dg/min, preferably from 4.9 to 15.4 dg/min, morepreferably from 6.1 to 11.5 dg/min as measured according to ASTMD1238-13 with a 2.16 kg load at 190° C., wherein the density of the highdensity polyethylene is in the range from 0.920 to 0.972 g/cm³,preferably from 0.953 to 0.970 g/cm³, more preferably from 0.960 to0.968 g/cm³ as measured according to ASTM D792-13.

Optional Additives

The polymer composition according to the present invention may furthercontain additives, for instance nucleating agents and clarifiers,stabilizers, release agents, plasticizers, anti-oxidants, lubricants,antistatics, cross linking agents, scratch resistance agents, highperformance fillers, pigments and/or colorants, flame retardants,blowing agents, acid scavengers, recycling additives, anti-microbials,anti-fogging additives, slip additives, anti-blocking additives, polymerprocessing aids and the like. Such additives are well known in the art.The amount of the additives is preferably to be at most 5.0 wt %,preferably at most 4.5 wt %, preferably at most 4 wt %, more preferablyat most 3.8 wt % based on the total amount of the polymer composition.The reason for the preference of the low amount of additives is that atthis amount, additives do not have negative influence on the desiredproperties of the polymer composition according to the presentinvention.

Polymer Composition

The polymer composition according to the present invention comprisessaid first heterophasic propylene copolymer (a), said secondheterophasic propylene copolymer (b), optional inorganic filler,optional polyolefin based elastomer and optional additives wherein theamount of the first heterophasic propylene copolymer (a) is in the rangefrom 4.6 to 70.4 wt %, preferably from 10.1 to 54.8 wt %, preferablyfrom 15.2 to 47.7 wt %, preferably from 22.9 to 40.1 wt % based on thetotal amount of the polymer composition, wherein the amount of thesecond heterophasic propylene copolymer (b) is in the range from 4.3 to69.8 wt %, preferably from 6.5 to 60.1 wt %, preferably from 8.2 to 40.1wt % based on the total amount of the polymer composition.

The total amount of the first heterophasic propylene copolymer (a), thesecond heterophasic propylene copolymer (b), the optional polyolefinbased elastomer, the optional inorganic filler and the optionaladditives is at least 95 wt %, preferably at least 97 wt %, preferablyat least 98.5 wt % and preferably at most 100 wt % based on the totalamount of the polymer composition.

The amount of the inorganic filler is preferably in the range from 2.5to 31.0 wt %, preferably from 3.4 to 25.6 wt %, more preferably from 4.6to 20.7 wt %, more preferably from 5.7 to 17.3 wt %, most preferablyfrom 6.5 to 15.2 wt % based on the total amount of the polymercomposition.

The MFI of the polymer composition is in the range from 5 to 100 dg/min,preferably from 10 to 70 dg/min, more preferably from 15 to 50 dg/min,more preferably from 15 to 25 dg/min as measure according toISO1133-1:2011 with a 2.16 kg load at 230° C. as in the preferred MFIrange, the polymer composition has an optimal balance between impactperformance and processability.

The polymer composition according to the present invention can forexample be prepared in an extrusion process by melt-mixing the firstheterophasic propylene copolymer, the high density polyethylene, thesecond heterophasic propylene copolymer, the optional polyolefinelastomer, the optional inorganic filler and the optional additives inan extruder.

The present invention further relates to a process for the preparationof an article, preferably an automotive part, comprising the sequentialsteps of:

-   -   Providing the polymer composition according to the present        invention;    -   Shaping the polymer composition according to the present        invention in to the article, preferably by injection molding.

The present invention further relates to the use of the polymercomposition according to the present invention in the preparation of anarticle, preferably an automotive part, for example an automotiveinterior part, for example an automotive exterior part.

The present invention further relates to an article, preferablyinjection molded article, more preferably injection molded automotivearticle obtained or obtainable by the process of the present invention,wherein the amount of the polymer composition according to the presentinvention is at least 95 wt %, preferably at least 98 wt % based on thetotal amount of the article.

For the avoidance of any confusion, in the context of the presentinvention, the term “amount” can be understood as “weight”; “Melt flowindex (MFI)” refers to the same physical property as “melt flow rate(MFR)”.

It is noted that the invention relates to all possible combinations offeatures described herein, preferred in particular are thosecombinations of features that are present in the claims. It willtherefore be appreciated that all combinations of features relating tothe composition according to the invention; all combinations of featuresrelating to the process according to the invention and all combinationsof features relating to the composition according to the invention andfeatures relating to the process according to the invention aredescribed herein.

It is further noted that the term ‘comprising’ does not exclude thepresence of other elements. However, it is also to be understood that adescription on a product/composition comprising certain components alsodiscloses a product/composition consisting of these components. Theproduct/composition consisting of these components may be advantageousin that it offers a simpler, more economical process for the preparationof the product/composition. Similarly, it is also to be understood thata description on a process comprising certain steps also discloses aprocess consisting of these steps. The process consisting of these stepsmay be advantageous in that it offers a simpler, more economicalprocess. When values are mentioned for a lower limit and an upper limitfor a parameter, ranges made by the combinations of the values of thelower limit and the values of the upper limit are also understood to bedisclosed.

The invention is now elucidated by way of the following examples,without however being limited thereto.

Materials

PP5.5 is a grade commercially available from SABIC under the same gradenames. PP5.5 is a shift grade. The properties of PP5.5 are in Table 2.

Polymer A, B, C and D are heterophasic propylene copolymers prepared inan Innovene™ process, wherein a sequential two-reactor setup wasemployed. Polypropylene homopolymers were produced in first reactor andpropylene-ethylene copolymers were produced in the second reactor.

There were three component in the catalyst system in the polymerizationprocess: A procatalyst, an external electron donor and a co-catalyst.The procatalyst was prepared according to the description inWO2016198344, page 36, “Procatalyst III” paragraph; The externalelectron donor used for Polymer A and B was di(iso-propyl)dimethoxysilane (DiPDMS), the external electron donor used for Polymer Cand D was n-propyltriethoxysilane (nPTES); the co-catalyst wastriethylaluminium.

The process condition of Polymer A, B, C and D are given in Table 1:

TABLE 1 Preparation condition of Polymer A, B, C and D Polymer A B C DR1 Te (° C.) 66 66 69.5 69.5 R1 Pr (Bar) 24 24 24 24 Al/Ti (mol/mol) 135135 135 135 Si/Ti (mol/mol) 10 10 10 10 R1 H2/C3 (mol/mol) 0.08 0.050.01 0.065 R1 split (wt %) 80 74 76 86 R2 Te (° C.) 66 57 66 59 R2 Pr(Bar) 24 24 24 24 R2 H2/C3 (mol/mol) 0.132 0.005 0.011 0.0042 R2 C2/C3(mol/mol) 0.63 0.33 0.3 0.31 R2 split (wt %) 20 26 24 14

In Table 1, R1 refers to the first reactor, R2 refers to the secondreactor, Te refers to temperature, Pr refers to pressure, Al/Ti is themolar ratio of the co-catalyst to the procatalyst, Si/Ti is the molarratio of the external donor to the procatalyst, H2/C3 is the molar ratioof hydrogen to propylene, C2/C3 is the molar ratio of ethylene topropylene, split is the amount of substance produced in R1 or R2 basedon the amount of the total Polymer A or B or C or D respectively.

HDPE 80064 is an HDPE commercially available from SABIC with grade nameHDPE M800645 having a density of 0.964 g/cm3 (ASTM D792-13) and an MFIof 8.0 g/10 min (ASTM D1238-13, 2.16 kg, 190° C.).

Tafmer D605 is an ethylene based elastomer, commercially available fromMitsui Chemicals, having a density of 0.861 g/cm3 (ASTM D792-13), an MFIof 0.5 g/10 min (ASTM D1238-13, 2.16 kg, 190° C.) and a shore A hardnessof 58 (ASTM D2240-15).

Engage 8200 is a polyolefin elastomer commercially available from Dow,having a density of 0.870 g/cm3 (ASTM D792-13), an MFI of 5.0 g/10 min(ASTM D1238-13, 2.16 kg, 190° C.) and a shore A hardness of 66 (ASTMD2240-15).

Luzenac HAR T84 is a high aspect ratio talc commercially available fromImerys Talc. The mean particle size of talc (D50) of Luzenac HAR T84 is2 micron as measured according to sedimentation analysis, Stockes' law(ISO 13317-3:2001).

Additive package consists of 50 wt % color masterbatch, 20 wt % heat andprocess stabilizers, 10 wt % UV stabilizer, 20 wt % processing aid basedon the total amount of the additive package.

Sample Preparation Compounding

Pellets of Examples were prepared by compounding the components in Table3 in a KraussMaffei Berstorff ZE40A_UTX 43D twin-screw extruder with thefollowing setting: 400 rpm screw speed, 150 kg/h through put, 38%torque, 235° C. as temperature and 13 bar as head pressure.

Specimens Preparation

Specimens for the measurement were prepared by injection molding. Thedimensions of the specimens used in tensile test are defined in ISO527-2 type 1(a); The dimensions of the specimens used in impactresistance test are defined in 150180/1A; The dimensions of thespecimens used in gloss measurement are 65*65*3.2 mm.

Test Method Melt Flow Index

Melt flow index (MFI) was measured according to ISO1133-1:2011 at 230°C. with a 2.16 kg load.

Weight percentage of the xylene-soluble part (CXS) and weight percentageof the xylene-insoluble part (CXI)

Weight percentage of the xylene-soluble part (CXS) of the heterophasicpropylene copolymers was determined according to ISO16152:2005. Weightpercentage of xylene-insoluble part (CXI) of the heterophasic propylenecopolymers was calculated using the following equation:

CXI=100 wt %−CXS

Both xylene-soluble and xylene-insoluble parts (CXS and CXI) obtained inthis test were used in the intrinsic viscosity (IV) test.

Intrinsic Viscosity (IV)

Intrinsic viscosity (IV) of CXS and CXI was determined according toISO1628-1:2009 and ISO1628-3:2010 respectively in decalin at 135° C.

Impact Resistance

Impact resistance is determined according to Izod ISO180:2000 at 23° C.

Tensile Modulus

Tensile modulus was determined according to ISO527-1:2012 at 23° C.

Gloss

Gloss at 20° and 60° was determined according to ISO2813:2014.

Result

TABLE 2 Properties of HECOs Polymer Polymer Polymer Polymer PP5.5 A B CD MFI (g/10 min) 5.5 40 14 12 77 Weight fraction — 80 74 76 86 matrix(wt %) MFI matrix — 75 85 35 230 (g/10 min) CSX (wt %) 30 18 22 22 14IV_(CXS) (dl/g) 2.2 2.2 4.0 1.9 5.3 IV_(CXI) (dl/g) 1.9 1.3 1.4 1.3 1.3Reactor grade No Yes Yes No Yes

TABLE 3 Properties of PPc CE1 IE1 IE2 IE3 Polymer A (wt %) 49.6 35.622.6 30.6 Polymer B (wt %) 13.0 Polymer C (wt %) 15.0 Polymer D (wt %)30.0 30.0 20.0 PP5.5 (wt %) 5.0 15.0 Tafmer DF605 20.0 9.0 20.0 (wt %)Engage 8200 18.0 9.0 (wt %) Luzenac HAR T84 13.0 13.0 13.0 13.0 (wt %)Additives (wt %) 1.4 1.4 1.4 1.4 MFI (dg/min) 18.2 22.6 16.9 19.9 Impactresistance 42 41 47 43 (kJ/m2) Tensile modulus 1329 1481 1439 1410 (MPa)Gloss 20° 42.9 8.7 21.3 8.7 Gloss 60° 68.8 27.7 47.5 27.8

According to the information in Table 3, the polymer compositions of theinvention as exemplified by IE 1-3 how low gloss while maintainingmechanical properties such as impact resistance and tensile modulus anda good MFI (Suitable for injection molding).

1. A polymer composition comprising a first heterophasic propylenecopolymer (a), a second heterophasic propylene copolymer (b) andoptionally an inorganic filler, wherein the amount of the firstheterophasic propylene copolymer (a) is in the range from 4.6 to 70.4 wt% based on the total amount of the polymer composition, wherein theamount of the second heterophasic propylene copolymer (b) is in therange from 4.3 to 69.8 wt % based on the total amount of the polymercomposition, wherein the first heterophasic propylene copolymer (a)comprises: from 80 to 92 wt % of a propylene polymer (a1); from 8 to 20wt % of an ethylene-α-olefin copolymer (a2), wherein the moiety ofα-olefin in the ethylene-α-olefin copolymer (a2) is derived from atleast one α-olefin having 3 to 20 carbon atoms; wherein the melt flowindex (MFI) of the first heterophasic propylene copolymer (a) is in therange from 40 to 120 dg/min as determined according to ISO1133-1:2011 at230° C. with a 2.16 kg load, wherein the amount of the xylene-solubleportion of the first heterophasic propylene copolymer (a) is in therange from 10 to 27 wt % based on the total amount of the firstheterophasic propylene copolymer (a) as determined according toISO16152:2005, wherein the ratio between the intrinsic viscosity of thexylene-soluble part IV_(CXS) and the intrinsic viscosity of thexylene-insoluble part IV_(CXI) of the first heterophasic propylenecopolymer (a) is in the range between from 3.1 to 7.2 wherein IV_(CXS)and IV_(CXI) are measured according to ISO1628-1:2009 and ISO1628-3:2010respectively. wherein the second heterophasic propylene copolymer (b)comprises: from 65 to 81 wt % of a propylene polymer (b1), from 19 to 35wt % of an ethylene-α-olefin copolymer (b2), wherein the moiety ofα-olefin in the ethylene-α-olefin copolymer (a2) is derived from atleast one α-olefin having 3 to 20 carbon atoms, wherein the MFI of thesecond heterophasic propylene copolymer (b) is in the range from 10 to100 dg/min as determined according to ISO1133-1:2011 at 230° C. with2.16 kg load, wherein the MFI of the polymer composition is in the rangefrom 5 to 100 dg/min as determined according to ISO1133-1:2011 at 230°C. with 2.16 kg load.
 2. The polymer composition according to claim 1wherein the amount of the first heterophasic propylene copolymer (a) isin the range from 10.1 to 54.8 wt %, based on the total amount of thepolymer composition.
 3. The polymer composition according to claim 1,wherein the MFI of the propylene polymer (a1) in the first heterophasicpropylene copolymer (a) is in the range in the range from 150 to 300dg/min, as determined according to ISO1133-1:2011 at 230° C. with 2.16kg load.
 4. The polymer composition according to claim 1, wherein theratio between the intrinsic viscosity of the xylene-soluble partIV_(CXS) and the intrinsic viscosity of the xylene-insoluble partIV_(CXI) of the first heterophasic propylene copolymer (a) is in therange between from 3.2 to 5.1 wherein IV_(CXS) and IV_(CXI) are measuredaccording to ISO1628-1:2009 and ISO1628-3:2010 respectively.
 5. Thepolymer composition according to claim 1, wherein the intrinsicviscosity of the xylene-insoluble part (CXS) of the first heterophasicpropylene copolymer (a) IV_(CXS) is in the range from 4.5 to 6.5 dl/g,as measured according to ISO1628-1:2009.
 6. The polymer compositionaccording to claim 1, wherein the intrinsic viscosity of thexylene-soluble part (CXI) of the first heterophasic propylene copolymer(a) IV_(CXI) is in the range from 1.0 to 2.0 dl/g, as measured accordingto ISO1628-3:2010.
 7. The polymer composition according to claim 1,wherein the amount of the second heterophasic propylene copolymer (b) isin the range from 6.5 to 60.1 wt %, based on the total amount of thepolymer composition.
 8. The polymer composition according to claim 1,wherein the MFI of the second heterophasic propylene copolymer (b) is inthe range from 15 to 80 dg/min, as determined according toISO1133-1:2011 at 230° C. with 2.16 kg load.
 9. The polymer compositionaccording to claim 1, wherein the inorganic filler is talc.
 10. Thepolymer composition according to claim 1, wherein the propylene polymer(a1) in the first heterophasic propylene copolymer (a) is a propylenehomopolymer or/and the propylene polymer (b1) in the second heterophasicpropylene copolymer (a) is a propylene homopolymer.
 11. The polymercomposition according to claim 1, wherein the ethylene-α-olefincopolymer (a2) in the first heterophasic propylene copolymer (a) is anethylene-propylene copolymer or/and the MFI of the propylene polymer(b1) in the second heterophasic propylene copolymer (b) is in the rangefrom 20 to 150 dg/min, as determined according to ISO1133-1:2011 at 230°C. with 2.16 kg load.
 12. The polymer composition according to claim 1,wherein the first heterophasic propylene copolymer (a) and/or the secondheterophasic propylene copolymer (b) are reactor grades.
 13. A processfor the preparation of an article comprising the sequential steps of:providing the polymer composition of claim 1; and shaping the polymercomposition into the article.
 14. The process according to claim 12,wherein the article is an automotive part.
 15. (canceled)
 16. Thepolymer composition according to claim 1, wherein the wherein the amountof the first heterophasic propylene copolymer (a) is in the range from15.2 to 47.7 wt %, based on the total amount of the polymer composition.17. The polymer composition according to claim 1, wherein the whereinthe amount of the first heterophasic propylene copolymer (a) is in therange from 22.9 to 40.1 wt % based on the total amount of the polymercomposition.
 18. The polymer composition according to claim 1, whereinthe amount of the second heterophasic propylene copolymer (b) is in therange from 8.2 to 40.1 wt % based on the total amount of the polymercomposition.